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CONCRETE PIPES AND MANHOLES
Schlüsselbauer Technology GmbH & Co KG, 4673 Gaspoltshofen, Austria
Monolithic up to DN1800 – Tracey Concrete enters
a new dimension in the production of customised
concrete manhole bases in UK and Ireland
Since more than 10 years the Perfect manufacturing system conforms to the latest accepted state of the art to produce custom-made wetcast monolithic concrete manhole bases. In particular the excellent quality of the tailored concrete channel, which is produced by using preformed polystyrene rigid foam parts as well as an optimised resource management that leads to high economic efficiency are reasons for
the international success of this production system developed by Schlüsselbauer Technology. Tracey Concrete, one of the largest precast concrete manufacturers in the UK and Ireland, is the next prominent plant that recently launched its production of wet-cast, monolithic concrete
manhole bases with individually tailored channel configuration. Beside the qualitative arguments Tracey Concrete took the decision for the
Perfect technology also because of the fact, that this manufacturing system allows the production of mono bases with very large diameters.
Thereby, the company is now to produce individually tailored manhole bases in diameter DN1800 that are made in only one pour with a
proven industrial process.
Ralph Mitterbauer,
Schlüsselbauer Technology GmbH & Co KG, Austria
The traditional Northern Irish company
Tracey Concrete Limited is situated in
Enniskillen, County Fermanagh and produces a wide variety of top quality products, such as pipes, jacking pipes, manhole
bases, manhole rings and other precast
concrete components that are used for different sewage and water drainage systems.
Over the last 30 years, the company has
become well known as a competent and
reliable supplier of major construction projects throughout the UK and Ireland. For
example as part of the construction of
Terminal 2 of Dublin airport or during the
highway A8 upgrade from Belfast to Lane.
In both cases concrete pipes and manhole
components from Tracey concrete were
used. The strategic investment in the Perfect
manufacturing system from Schlüsselbauer
Technology represents the next logical step
for the company to approach and to
expand a leading position in the AngloSaxon precast concrete market.
World premiere: Monolithic Perfect manhole bases from one pour up to DN1800
Due to local regulations regarding maximally permitted pipe connection sizes it
was one main concern for Tracey Concrete
that the new manufacturing system is able
to produce monolithic manhole bases with
individually tailored channel configurations
Company premises of Tracey Concrete Limited in Enniskillen,
County Fermanagh Northern Ireland.
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also in large diameters up to 1800 mm. The
Perfect method makes it possible for the first
time to manufacture bases of this diameter
in an economic and mainly automated
process. The scope of supply of the Perfect
manufacturing system included a dozen of
casting moulds with can be used to produce concrete mono bases in nominal
widths of DN1200, DN1500 and now also
in a diameter of 1800 mm that are all made
in only one pour. The height of the manhole
components differs from 700 mm at
DN1200 up to max. 1600 mm at DN1800
and can be easily adapted in the mould
apparatus. The wall thickness differs from
150 up to 300 mm in the maximum version.
The manhole bases can be equipped with
or without step rungs. Optionally, Tracey
Monolithic concrete manhole bases with individually tailored
channels from the current production.
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also offers its customers manhole bases
with pre-integrated lifting anchors to make
the handling on the building site safer and
faster.
Individual and flexible:
The Perfect manufacturing system
The exact and flexible dimensional accuracy of channels and pipe connections is the
critical factor in the production of manhole
bases. With the Perfect system Schlüsselbauer Technology developed a time-tested
and permanently improved solution which
makes it possible to manufacture concrete
manhole bases cast in one pour and allows
for virtually every functional channel configuration. Infinite variability of the angulation and incline of all inlets makes it possible to optimise the flow behaviour throughout the course of the channel. Areas of congestion and unwanted turbulence are
avoided by maintaining a constant incline
throughout the entire section of channel.
The optimised hydraulic lowers abrasion
and leads to longer maintenance cycles
too. The system allows the easy production
of all channel configurations that are
required by communal sewage systems in
only one manhole base. Any requested
changes of direction, diameters, multiple
outlets or differing heights of the berm can
be considered too.
Tracey Concrete produces customised concrete manhole bases with a diameter
of 1800 mm by using EPS forming parts.
Another advantage of the Perfect manufacturing system is the possibility to use factoryintegrated gaskets. If required, seals are
pre-assembled on the simulating pipe connection forms in the plant and are firmly
bonded with fluid concrete afterwards.
In the Perfect process only easy or self compacting concrete is used that cures in the
formwork. Thus, it ensures the geometric
precision of all joints alongside a high-quality surface with an extremely low water
penetration depth. Beside the high level of
resistance to chemical attacks, concrete
manhole bases manufactured in one pour
display excellent scientifically tested characteristics relating to compression strength
and abrasion resistance.
In combination with the consistent packing
tightness of the components monolithic
structure an estimated product lifetime of
the Perfect manhole base of more than 100
years can be achieved.
Tailor-made channels due
to intelligent moulding program
By choosing the Perfect manufacturing system Tracey Concrete is able to produce cuswww.cpi-worldwide.com
The high quality concrete surface of Perfect manhole bases contributes to an estimated
product lifetime of more than 100 years.
tomised manhole bases with individually
tailored channel configurations that are
made in only one pour. The centrepiece of
the Perfect technology is an elaborated
moulding program for the individual channel configuration. Prefabricated elements
made from polystyrene rigid foam (= EPS),
like arcs, straight lines or pipe connection
moulds can be easily fixed together to one
single negative mould unit. On behalf of
Schlüsselbauer the EPS-mould parts were
already designed in such a way that commonly used channel configurations can be
produced with a minimum of material input.
Necessary cuttings are done by a sophisticated hot wire technology. All data is transCPI – Concrete Plant International – 1 | 2016
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CONCRETE PIPES AND MANHOLES
Computer-controlled hot wire cutters are used to cut the negatives for
the required channel components accurately.
ferred to the saws from an easy to operate
planning programme, which is previously
used to configure the manhole base on the
computer.
Thanks to the Perfect moulding program
Tracey Concrete is able from now on to produce all pipe and channel diameters from
DN100 to DN1000 in a precise and easy
way. In order to satisfy specific customer
requirements quickly it is very important for
Tracey, to possess an automated largescale production of manhole components
with individual pipe connections and channel configurations. The exactly tailored
channel components made from polystyrene rigid foam are then glued together
to one single unit. Afterwards the finished
negative channels are placed into the steel
moulds. After the closing of the moulds they
are filled with fluid concrete using a crane
track and a concrete bucket.
In this way, complete manhole bases with
bottom, wall, berm and requested channel
are produced in only one work step. The
products cure in the mould and can already
be removed on the next working day. First
both halves of the casing are pulled apart
manually. Afterwards the component is
taken out by a gripper, turned 180° and is
set down in the end. Following up, the rigid
foam parts are removed from the manhole
base by using simple tools.
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Exactly shaped pipe connection form made from EPS
(polystyrene rigid foam).
Strong market position for concrete
manhole components in UK and Ireland
The declared aim of Tracey Concrete is to
improve its strong market position regarding product quality and production costs in
the segment of manhole components.
The Perfect technology allows the company
to manufacture top-quality concrete manhole bases with precisely fitting pipe connections that are made in only one pour in
a very short time.
Patrick Thomas Tracey, CEO of Tracey
Concrete sums it up: “The decision for the
Perfect manufacturing system from Schlüsselbauer Technology is a milestone for our
company on the way to the market leadership in the manhole production segment in
UK and Ireland. In particular we see the
possibility to satisfy specific customer
requirements in an economic and mostly
automated production process as a strategic advantage that definitely stands out
from the competition.”
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FURTHER INFORMATION
Tracey Concrete Limited
Old Rossorry, Sligo Road
Enniskillen, Co. Fermanagh
BT74 7LF, Northern Ireland
T +28 6632 6437
F +28 6632 4908
[email protected]
www.traceyconcrete.com
Schlüsselbauer Technology GmbH & Co KG
Hörbach 4, 4673 Gaspoltshofen, Austria
T +43 7735 71440
F +43 7735 714456
[email protected], www.sbm.at
www.perfectsystem.eu
www.cpi-worldwide.com
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ENGLISCH
PERFEC T PIPE
T HE S A NI TA R Y S E W ER P IP E
T H AT S TA NDS T HE T E S T OF T IME
CORROSION RESISTANT
EXCEPTIONAL STRENGTH
CREATES HIGH VALUE
IN MANUFACTURING OF PRECAST
CONCRETE ELEMENTS
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